A7 CNC Machining Centre

INDO-GERMAN TOOL ROOM, AURANGABAD
CHAPTER : A7 – CNC MACHINING CENTRE TG2
CHAPTER OUTLINE
A7.1 – Introduction & Classification
A7.2 – Machine Parts & Description
A7.3 – Cutting tools
A7.4 – Work & Tool holding devices
A7.5 – Safety precautions
A7.1 Introduction & Classification of machine
TOPIC OUTLINE
a) Classification
Machining Centre
Machining center were developed in the 1960's so that a part did not have to be moved
from machine to machine in order to perform various operations. These machines greatly
increased production rates because more operations could be performed on a work piece
in one set.
These are to main types of machining centers, horizontal & vertical spindle types.
Machining centers are capable of performing a variety of machining operations on a work

piece.
A7.1a CLASSIFICATION
METAL WORKING TECHNIQUE WITH CNC MACHINE TOOLS

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Horizontal spindle machining centers have three axes of motion.
Vertical spindle machining centers have three axes of motion.
a). The Horizontal spindle machining center operates on three axes:
1 The X-axis controls the table movement left or right.

2 The Y-axis controls the vertical movement (up or down) of the spindle.
3 The Z-axis controls the horizontal movement (in or out) of the spindle.
b). The vertical spindle machining center operates on three axes:
1 The X-axis controls the table movement left or right.

2 The Y-axis controls the table movement toward or away from column.
3 The Z-axis controls the vertical movement (up or down) of the spindle.

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A fixed column machining centre with a Pallet shuttle
CNC Machining centre with a tool change storage drum

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SUMMARY
At the end of this topic student shall be able to –
 Know about the types of the CNC Machining centre
 Classify the CNC Machining centre
In the next topic students are going to learn about machine parts and description of CNC
Machining centre.
QUESTION BANK
Questions:
1) What is CNC Machining Centre?
2) How CNC Machining Centre is classified?
3) With the help of net sketch, label various axes on CNC Machining Centre.

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A7.2 MACHINE PARTS & DESCRIPTION
TOPIC OUTLINE
a) Features of Machine
b) Parts of machine
c) Specifications
A7.2a FEATURES OF THE MACHINING CENTER

A7-5
A7.2a FEATURES
OF THE MACHINING CENTER -
1. Mechanize castings for greater strength, stiffness and accuracy.

2. Extra wide and long saddle provides maximum machining stability.
3. Four wide sideways on the VMC-2100 are one-piece machined to give additional
incredible solid support for 3D contouring.
4. Oversize, box-type columns are out -fastened to the bases for added stability and
rigidity.

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5. Sideways is extra -wide, hardened & precision ground. Extra-long slide ways
connections ensure vibration -free traverse of the headstock.
6. The headstock is one -piece constructed the rib reinforced structure provides solid
support for the spindle.
7. Precision ball screws on all three axes in conjunction with a powerful motor drive
deliver an exceptionally smooth &steady feed.
8. Sideways are precision scraped and coated with Turcite-B.
9. Automatic lubrication is controlled by a timing device.
10. Special slant beam design at 60 degree distributes axial force evenly over the
beam surface.
11. One piece cast, extra -heavy columns.
12. Short distance from spindle center to beam surface ensures stability for extra -
heavy machining operations.
13. Long distance between columns (up to 3,000mm).
14. High precision, pre-tensioned ball screws reduce thermal strain and maintain high
positioning accuracy.
15. Specially designed tool released prevents damage to the spindle bearings.
16. Forced cooling of the spindle, bearings and gearbox prevent thermal expansion
and ensure a constant spindle temperature.

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A7.2b PARTS OF CNC MACHINING CENTERS:
The main parts of CNC machining centers are the bed, saddle, column, table servomotors,
ball screws, spindle, tool changer & the machine control unit (MCU) (Fig. 9.4).
Bed- The bed is usually made of high quality cast iron, which provides for a rigid machine
capable of performing heavy duty machining & maintaining high precision. Hardened &
ground ways are mounted to the bed to provide rigid support for all linear axes.
Saddle- The saddle, which is mounted on the hardened & ground bed ways, provides the
machining center with the X-axis linear movement.
Column- The column, which is mounted to the saddle, is designed with high torsional
strength to prove distortion & deflection during machining. The column provides the
machining center with the Y-axis linear movement.
Table- The table, which is mounted on the bed (fig.9.5), provides the machining center with
the Z-axis linear movement.
Servo system- the servo system, which consist of servo drive motors, ball screws &
position feed back encoders, provides fast, accurate movement & positioning of the XYZ
axes slides. The feed-back encoders mounted on the ends of the ball screws form a
Closed-loop system, which maintains consistent high positioning unidirectional repeat-
Ability of +-0.0001in. (0.003mm).

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Spindle- The spindle, which is programmable in 1-r/min increments, has a speed range of
from 20-6000 r/min. The spindle can be of a fixed position (horizontal) type, or can be a
tilting/contouring which provides for an additional (A) Axis (fig.9.6)
Tool changers- there are basically two types of tool changers, the vertical tool changer
(fig.9.7) & the horizontal tool changer (fig.9.8). The tool changer is capable of storing a
number of preset tools, which can be automatically called for use by the part
Program. Tool changers are usually bi-directional, which allows for the shortest travel
distance to randomly access a tool. The actual tool change time is usually only 3 to 5 sec.
MCU- The MCU allows the operator to perform a variety of operations such as
programming machining, diagnostics, tool & machine monitoring, etc. MCUs vary
according to manufacturers specifications; new MCUs are becoming more sophisticated,
making machine tools more reliable & the entire machining operations less dependent on
human skills.
PALLET CHANGER
Pallet changer is a direct savings attachment. The simplest & the cheapest option are to go
for a manual pallet changer. Manual pallet changer is an appropriate product for Indian
conditions & this philosophy is now fully accepted in the western world & more & more
acceptance is taking place in the Indian context. The manual pallet changer is a fully
functional reliable & efficient work changing system, which is basically a very simple
mechanical contraption.
Palletizing is the direct solution to cut down the idle time required to change work piece.
The automatic pallet changer is the well-known concept in the machining center.
MANUAL PALLET CHANGER
The manual pallet changer is not yet popular in the Indian sub-continent. However, today
we see the population growing & more people are buying the idea of using Manual pallet
changers.

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We have appropriate technology to bring awareness to the Indian user. Manual pallet
changers are very popular in the US & JAPAN. We know at least 3-companies in the
U.S.A. & 2-companies in JAPAN who produces Manual pallet changers in quantities. We
have also come across Manual pallet changer manufacturing companies in Taiwan, Korea
& U.K.
WHY MANUAL PALLET CHANGER
a) Economical: very often-vertical machining centers/ Drill Tap centers are not purchased
along with the Automatic pallet changers or the particular model purchased may not have
Automatic pallet changer. The Automatic pallet changer is a complex system, which
increases overall manufacturing lead-time as well as the cost. Vertical machining centers
when purchased without pallet changer for regular volume production activities are
definitely compromising productivity as the work changing can absorb a large portion of the
productive time. Hence the Manual pallet changer is the solution to improve productivity.
b) Flexibility: Sometimes machining centre user buy Manual pallet changer along with their
machine in lieu of an automatic pallet changer. This is due to various Flexibility available
for him such as multiple pallets being used as fixture bases so that the user can switch
pallet to effect work changing. This provides low cost solution, at the same time providing
greater Flexibility also the manual pallet changer being a simple gadget, can always be
removed from the machine when ever customer needs bigger envelop for a special, once
in while job.
c) Quick pallet change time: pallet change time is low at an average of 10-15 sec., which
is generally faster than the automatic pallet changer.

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MACHINE AXES:
Machining centers have probably made the greatest impact in NC machining because of
their ability to perform such a variety of machining operations on all side of a work piece
with only one setup. The 5-axis machining center (fig, 9.9) indicates the axes that can be
used when performing these machining operations & sequences.
X axis linear movement

Y-axis Linear movement
Z-axis Linear movement
A axes Tilt/ contour spindle
B axis Rotary table

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A7.2c SPECIFICATIONS OF THE MACHINING CENTER

A7-12

A7-13
SUMMARY
 Understand the features of CNC Machining Centre
 Specify CNC Machining Centre
 Identify the main parts and their functions of CNC Machining Centre
In the next topic students are going to learn about cutting tools used on CNC Machining
Centre.
QUESTION BANK
Questions:
1) With the help of neat sketch label the machine parts.
2) Describe the features of CNC Machining Centre.
3) What is MCU and what is its function?

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A7.3 CUTTING TOOLS
TOPIC OUTLINE
a) Milling cutters
b) Speeds & Feeds
A7.3a MILLING CUTTERS
The selection of proper cutting tool for each operation on a machining center is essential to
producing an accurate part. Generally there is not enough thought and planning going in
the selection of cutting tool for each particular job. The NC programmer must have a
through knowledge of cutting tools and their application in order to properly program any
part.
Machining center \s use a variety of cutting tool perform various machining operations.
These tools may conventional high-speed steel, cemented carbide inserts, CBN (cubic
boron nitride) inserts, or polycrystalline diamond inserts tool. Some of the tools used are
end mills, drills, taps, reamers, boring tools, etc.
Studies shows that machining center times consist of 20 percent milling, 10 percent boring,
and 70 percent hole marking is an average machining cycle. On convention milling
machine, the cutting tool cuts approximately 20 percent of the time, while on machining
center cutting time can be high as the 75 percent. The end result is that there is a large
consumption\ion of disposals tool due to decreased tool life through increased tool life.
END MILLS
End mills & shell end mills are widely used in machining centers. They are capable of
performing variety of machining operations such as face, pocket, and counter milling; spot
facing; counter boring; and roughing and finishing of hole using circular interpolation.
DRILLS
Conventional as well as specials drills are used to produces holes. Always choose the
shortest drill that will produce a hole of required depth. As drill diameter and length
increases does the error in hole size and location. Stub drills are recommended for the
drilling on the increasing errors.

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CENTER DRILL
Center drills are used to provide an accurate whole location for the drill, which is to follow.
The disadvantage of using Center drills is that the small pilot drill can break easily unless
care is used. An alternative to the center drills to that Center drill is the piloting tool, which
has the 90 degree included angle and is widely used for spotting hole locations.
TAPS
Machine taps are designed to withstand the torque required to thread a hole. Tapping is
one of the\he most difficult machining operation to perform because of the following factor:
1) Inadequate chip clearance.
2) Inadequate supply of cutting fluid.
3) Course and fine threads in various materials.
4) Speed and feed of threading operations being governed by the lead of thread.
5) Depth of thread required.
REAMERS
Reamers are available in variety of designs and sizes. A reamer is a rotary end-cutting tool
used to accurately size and produce a good surface finish in a hole, which has been
previously drilled or bored.
BORING TOOLS
Boring is the operation of enlarging the previous drilled, bored or cored hole to an accurate
size and location with the desired surface finish. This operation preformed by single point
boring tool. When the boring bar is selected the length and diameter carefully considered:
as the ratio between length and diameter is increases the rigidity of boring bar decreases.
I.e. A boring bar with a 1:1 length to diameter ratio is 64 times more rigid than the ratio.

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A7-17
A7.3b SPEEDS & FEEDS
The most important factor affecting the efficiency of the machine on the machining center
is cutter speed, feed, and depth of cut. If a cutting tool is run to slowly, valuable time is
wasted, resulting in lost of production. Too high speed will create a too much heat and
friction at the cutting edge of the tool, when quickly dulls the cutter. This results in having a
stop the machine to either recondition or replace of cutter. Some where between these two
extremes is the efficient cutting speed for each material being cut?
Feed is the rate at which is fed into the revolving cutter. If the work is fed too slowly time
will be wasted, resulting a lost of production and cutter chatter, which shorten the life of
cutter, may occur. If work is fed too low cuts are taken instead of one deep cut or roughing
cut. There fore speed, feed and depth of cut are three important factors, which affect the
tool life of the cutting tool and the productivity of machine tool.
Charts and tables containing speed feeds and depth of cut are available from cutting tool
manufactures, machining handbooks, etc.

A7-18
SUMMARY
 Identify the various variety of cutters used in CNC Machining Centre
 Understand the concept of the speed and feed in CNC Machining Centre
In the next topic students are going to learn about work holding and tool holding devices
used on CNC Machining Centre.
QUESTION BANK
Questions:
1) Name various cutting tools used on CNC Machining Centre.
2) Explain use of single point boring tools.

A7-19
A7.4 WORK HOLDING DEVICES
TOPIC OUTLINE
a) Work Holding Devices
b) Tool Holding Devices
A7.4a Work Holding Devices

When the work piece is set up it is important to ensure that the set up be safe. The w/p
must be securely fastened and the set up must be rigid. Enough the clamping force which
will be sure that all work holding devices, generally specified by the programmer, should be
located in the proper position on the machine table. Failure to follow these instructions may
result in operator injury, damages to machine, or scraped to workshops.
TYPES OF WORK HOLDING DEVICES
Swivel-base vice- May be bolted to the table or sub plate. The swivel-base enables the
vice to be swiveled 360 degree in a horizontal plane.
Angle plates - Are L-shaped pieces of cast iron or steel accurately machined to a 90-
degree angle. They are made in variety of sizes and have holes or slots, which provide a
means for fastening the work piece.
V-block- is generally used in pairs to support round work. A U-shaped clamp may be used t
fasten the work in a V-block.

A7-20
Clamps or Straps - Are used to fasten the work to the table, angle plates, or fixture. They
are made in a variety of sizes and are usually supported at the end by a step block and
bolted to the table by a t-bolt. It is good practice to place the
Support Jacks – Are used to support the work piece to prevent the torsion of the work
piece during clamping.
Parallels –Are flat square or rectangular pieces of metal used to support the work piece for
set up.
Sub plates – Are generally flat plates that may be fitted to the machine table to provide
quick and accurate location of work pieces, work holding devices, or fixtures. The fixturing
holes on the sub plate are accurately located and, when set up on machine table in
relation to the machine datum, provide the program with known locating precisions.

A7-21
FIXTURES
NC eliminates many of the expensive jigs and fixtures which were previously necessary to
hold and locate work piece on conventional machine tools. The repetitive position
accuracy of an NC machine tool eliminates the need for guide bushings, which were
previously required to locate the cutting tool.
NC fixture is used to accurately locate a part and hold it securely for any machining
operations required. Fixture design should be kept as simple as possible so that the time
required to load and unload a part is kept as short as possible. Since this time is non-
productive time the savings here will result in corresponding savings in the cost of
producing a part. When designing a fixture to hold a part, you must consider the following
points:
1. Positive location: The fixture must hold a work piece securely enough to prevent the
work piece from linear movement in the X, Y and Z-axes, and rotational movement in the
either direction about each axis.
2. Repeatability: Identical parts should always be located in exactly the same location and
unloading cycles.
3. Ruggedness: fixture must be designed to withstand the shock occurring during the
machining and loading and unloading cycles.
4. Rigidity: The work piece must be held securely enough to prevent any movement due to
forces created by the machining operation.
5. Design: Modular fixtures using standard components are quicker to produce and less
costly than custom fixtures. They can also be quickly modified to accommodate differently
shaped parts.
6. Low profile: Parts of the fixture or the necessary damping devices to hold the part
should be designed so that there is free movement for the cutting tool at any point in the
machining cycle.
7. Part loading/unloading: The fixture and its clamping devices should be designed so that
they do not interfere with the rapid loading or unloading of a part.
8. Part distortion: The fixture should be designed so that gravity, machining forces, or
clamping forces does not distort the part being machined. Stress should never be put on a
part by the clamping forces; otherwise the machine part will distort when the clamping
forces are removed.

A7-22
Clamping Hints
1.Always place the bolt as close to the work as possible.
2.Place a piece of soft metal ("picking") between the clamps and the w/p to prevent
damage to the w/p and to spread the clamping force over a wide area.
3.Make sure the packing is not extending into the machining path of cutting tool.
4.Use the table slots to prevent round work from moving.
5.Use two clamp whenever possible.
6.Parts that do not lie flat should be shimmed to prevent the work from rocking. This will
also prevent distortion when the work is clamped.
7.Tighten clamping bolts evenly to prevent w/p distortion.

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A7.4 b TOOLING SYSTEMS
TOOL HOLDERS
The machining center, a multifunction machine tool, used a wide variety of cutting tools
such as drills taps, reamers, end mills face mills boring tools, etc, to perform various
machining operations on a work piece. For these cutting tools to be inserted into the
machine spindle quickly and accurately, all these axis must have the same taper shank
tool holders to suit the machine spindle, the most common taper used in NC machining
center spindles is the No.50 taper, which is a self releasing taper. The tool holder must
also have a flange or collar, for the tool change arm to grab, and a stud, tapped hole, or
some other device for holding the tool securely in the spindle by a power drawbar or other
holding mechanism.
When is preparing for a machining sequence, the tool assembly drawing is used to select
all the cutting tools required to machine the part. Each cutting tools is then assembled
offline in a suitable tool holder and preset to the correct length. Once all the cutting tools
are assembled and preset, they are loaded into specific pocket location in the machine's
tool storage magazine when they are automatically selected as required by the part
program.
TOOL IDENTIFICATION
NC machine tools use a variety of methods to identify the various cutting tools, which are
used for machining operations. The most common methods are: -
1 Two pocket locations

Tools for early machining centers were assigned a specific pocket. Location in the tool
storage magazine, and each tool was called up for use by part program.
2 Colded rings on tool holders

A special interchange device reader was used to identify some tools by special coded rings
on the tool holder.
3 Tool assembly number

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Most modern MCUs have a tool identification feature, which allows the part program to
recall a tool from the tool storage magazine pocket by using a five to eight tool assembly
number.
Each tool assembly number may be assigned a specific pocket in the tool storage
magazine by the tool data tape, by the operator using the MCU, or by a remote tool
management console.

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Extension Head
Side Milling Head

A7-26
900 HEAD
The specially designed angular head provides powerful cutting capability. Advanced
conical teeth positioning assures maximum accuracy for various machining applications.
The head also features hydraulic tool release for quick tool change & increased efficiency.
UNIVERSAL HEAD

A7-27
Chain Type Tool

Magazine
 A choice of arm type or armless type ATC.
 The high-speed chain type ATC is one of the most proficient ATC systems in the
industry. It uses a high quality hydraulic index motor to store & retrieve tools.
 Fully avoids spindle & bearing damage while changing tool.
 The loading & unloading of tools is conveniently & easily accomplished simply by
pressing a foot pedal.
 The automatic tool magazine door assures full protection for tool from chips & dust.
The
 Program controlled door opens & closes while changing tools.

A7-28
TWO HEAD CONFIGURATION (TS Series)
ARMLESS TYPE ATC

A7-29
SUMMARY
 Know various work holding devices used on CNC Machining Centre
 Know various tool holding devices used on CNC Machining Centre
 Identify the tooling system used on CNC Machining Centre
In the next topic students are going to learn about safety precautions.
QUESTION BANK
Questions:
1) Explain the applications of universal head used on CNC Machining Centre.
2) Describe the ATC.
3) Write short notes on tool identification and NC tool holders for CNC Machining
Centre.

A7-30
7.5 SAFETY PRECAUTIONS:
Security precautions on CNC machine tools:
The target of work security is to eliminate accidents & damages to persons, machines &
facilities at work site.
Basically the same work security precautions apply to working on CNC machines as to
conventional machines tools. They can be classified in three categories:
 Danger elimination:
Defects on machines & on all devices necessary for work need to be registered at
once.
Emergency exits have to be kept free.
No sharp objects should be carried in clothing.
Watches & rings are to be taken off.
 Screening & marking risky areas:
The security precautions & corresponding notifications are not allowed to be removed
or inactivated.
Moving & intersecting parts must be screened.
 Eliminating danger exposure:
Protective clothing must be worn to protect from possible sparks & flashes.
Protective glasses or protective shields must be worn to protect the eyes.
Damaged electrical cables are not allowed to be used.
When setting up & operating CNC machines the following is to be taken into consideration:
 In general, setting up is allowed only on machine, which has been switched off. The
only exceptions being the operations, which required the machine power to be
switched on such as resetting the work with tools.
 The operator should not go to the rotation or work area of the machine since within this
area the machine can automatically rotate the turret head or feed the tool carrier.
 The specific security precautions of the machine manufacturer have to be followed.

A7-31
The following security precautions are to be followed as well:
 Blocking system against loose parts or parts which have not been allocated correctly,
against auto generated movement of not fixed elements & against starting an
automatic
 Machining procedure before setting up work has been completed.
 Blocking system of the work part-clamping device when charging the CNC machine
manually.
 Keeping the security distance between the parts of the neighboring CNC machines
coming closet to the machine in a system where CNC machines are connected with
each other.
 Protection against chips & coolant splashes.
 Sucking of the machine room air.

A7-32
SUMMARY
 Understand the safety precautions on CNC Machining Centre
QUESTION BANK
Questions:
1) How the safety precautions are classified while working on CNC Machining Centre?
2) How protection is provided against chips and coolant splashes?
3) Why damaged electrical cable are not allowed to be used?

A7-33

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INDO-GERMAN TOOL ROOM, AURANGABAD

CHAPTER : A7 – CNC MACHINING CENTRE TG2

A7.1 Introduction & Classification of machine

Machining centers are capable of performing a variety of machining operations on a work

METAL WORKING TECHNIQUE WITH CNC MACHINE TOOLS

Horizontal spindle machining centers have three axes of motion.

Vertical spindle machining centers have three axes of motion.

a). The Horizontal spindle machining center operates on three axes:

1 The X-axis controls the table movement left or right.

b). The vertical spindle machining center operates on three axes:

1 The X-axis controls the table movement left or right.

METAL WORKING TECHNIQUE WITH CNC MACHINE TOOLS

A fixed column machining centre with a Pallet shuttle

CNC Machining centre with a tool change storage drum

METAL WORKING TECHNIQUE WITH CNC MACHINE TOOLS

 Classify the CNC Machining centre

METAL WORKING TECHNIQUE WITH CNC MACHINE TOOLS

A7.2 MACHINE PARTS & DESCRIPTION

A7.2a FEATURES OF THE MACHINING CENTER

METAL WORKING TECHNIQUE WITH CNC MACHINE TOOLS

1. Mechanize castings for greater strength, stiffness and accuracy.

METAL WORKING TECHNIQUE WITH CNC MACHINE TOOLS

METAL WORKING TECHNIQUE WITH CNC MACHINE TOOLS

A7.2b PARTS OF CNC MACHINING CENTERS:

METAL WORKING TECHNIQUE WITH CNC MACHINE TOOLS

MANUAL PALLET CHANGER

METAL WORKING TECHNIQUE WITH CNC MACHINE TOOLS

WHY MANUAL PALLET CHANGER

METAL WORKING TECHNIQUE WITH CNC MACHINE TOOLS

X axis linear movement

METAL WORKING TECHNIQUE WITH CNC MACHINE TOOLS

A7.2c SPECIFICATIONS OF THE MACHINING CENTER

METAL WORKING TECHNIQUE WITH CNC MACHINE TOOLS

METAL WORKING TECHNIQUE WITH CNC MACHINE TOOLS

 Specify CNC Machining Centre

METAL WORKING TECHNIQUE WITH CNC MACHINE TOOLS

A7.3 CUTTING TOOLS

A7.3a MILLING CUTTERS

METAL WORKING TECHNIQUE WITH CNC MACHINE TOOLS

METAL WORKING TECHNIQUE WITH CNC MACHINE TOOLS

METAL WORKING TECHNIQUE WITH CNC MACHINE TOOLS

A7.3b SPEEDS & FEEDS

METAL WORKING TECHNIQUE WITH CNC MACHINE TOOLS

METAL WORKING TECHNIQUE WITH CNC MACHINE TOOLS

A7.4 WORK HOLDING DEVICES

A7.4a Work Holding Devices

TYPES OF WORK HOLDING DEVICES

METAL WORKING TECHNIQUE WITH CNC MACHINE TOOLS

METAL WORKING TECHNIQUE WITH CNC MACHINE TOOLS

METAL WORKING TECHNIQUE WITH CNC MACHINE TOOLS

METAL WORKING TECHNIQUE WITH CNC MACHINE TOOLS

A7.4 b TOOLING SYSTEMS

1 Two pocket locations

2 Colded rings on tool holders

3 Tool assembly number

METAL WORKING TECHNIQUE WITH CNC MACHINE TOOLS

METAL WORKING TECHNIQUE WITH CNC MACHINE TOOLS

Side Milling Head

METAL WORKING TECHNIQUE WITH CNC MACHINE TOOLS

METAL WORKING TECHNIQUE WITH CNC MACHINE TOOLS

Chain Type Tool

 A choice of arm type or armless type ATC.

 Fully avoids spindle & bearing damage while changing tool.